Method for manufacturing synthetic decorative stone with inlays

ABSTRACT

A method for manufacturing a synthetic decorative stone with inlays includes steps of: cutting or scrunching a stone or other solid decorating materials into thin small pieces; putting the thin small pieces in a bottom of a larger mold; mixing various materials which can form a synthetic stone with adhesives and then dumping them into the mold; taking out the mixed materials with the thin small pieces surrounded therein from the larger mold after being solidified; and then polishing the surface of the side with the thin small pieces. In accordance with the present invention, the synthetic decorative stone with inlays is made by using of various materials, which saves stone materials, creates a new inlay art and increases the decorative effect.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a field of building stone, and moreespecially to a method for manufacturing a synthetic decorative stonewith inlays.

2. Background of the Invention

A natural decorative stone is one type of building stones which hasfunction of decoration and can be used for architectural decoration orfurniture tops. With the development of architecture conformation andstyles, more and more decorative stones are used. These decorativestones are exploited from nature. Continual increasing of exploiturerequirement aggravates destroying to nature.

A synthetic decorative stone is a kind of appropriate substitute ofnatural decorative stone, especially a synthetic decorative stone whichis made of some cut-off powder and fragments from natural decorativestones. Making use of synthetic decorative stones relieves theincreasing requirements to nature stones and enriches the varieties ofarchitectural materials. A synthetic decorative stone is provided for awide range of ornamental and architectural uses.

The art of the stone inlay was used even in the ancient India, but byfar this art is embodied by manual work none the less. However, it is ofcourse not ensured that each product of each-time production isidentical to another, so this art is unable to be industrialized, andthe manufacturer using this way can not have mass production based onthe identical design of the order from in modern commercial distributionfield.

BRIEF SUMMARY OF THE INVENTION

A primary object of the present invention is to provide a method formanufacturing a synthetic decorative stone which increases thedecorative effect through inlaying cut stones with different pattern andspecificity in a synthetic stone tile.

To achieve the above-mentioned object, a method for manufacturing asynthetic decorative stone with inlays comprises steps of: cutting orscrunching a stone or other decorative materials into thin small pieces;laying out the thin small pieces in a bottom of a mold as inlay units;mixing various materials which can form a synthetic stone with adhesivesand pigments then dumping them into the mold; taking out the mixedmaterials (a synthetic stone tile) with the thin small pieces from themold after a typical process of making a synthetic stone tile; and thenpolishing the surface of the side with the thin small pieces.

In accordance with the present invention, the method for manufacturing asynthetic decorative stone tile with inlays utilizes modern technologiessuch as ultrasonic or water jet, which brings high manufactureefficiency. Inlaying stones or other decorative materials with variouspatterns, shapes, and amounts into a synthetic stone tile with variouslayout method saves stone materials, enrich the varieties ofarchitectural decorative materials, and increases the decorative effect.

Other objects, advantages and novel features of the present inventionwill become more apparent from the following detailed description whentaken in conjunction with the accompanying drawings, in which:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view showing a synthetic decorative stone inaccordance with the preferred embodiment of the present invention, whichincludes a synthetic stone tile and a plurality of thin small piecesinlaid therein.

DETAILED DESCRIPTION OF THE INVENTION

A method for manufacturing a synthetic decorative stone with inlays inaccordance with a preferred embodiment of the present invention includessteps as follows:

At the step 1, referring to FIG. 1, on the basis of requirements ofdifferent designs, cutting or scrunching a stone or other decorativematerials into thin small pieces 12 with different shapes.

Then turn to the step 2, laying out a plurality of thin small pieces ata bottom of a larger mold (not shown) according to a predeterminedpattern.

At the step 3, mixing various materials which can form a synthetic stonewith adhesives and pigments then dumping them into the mold. The variousmaterials include at least on kind of materials among marble power,quartzite power or fragments, granite power or fragments, and aluminapowder. The various materials are mixed with adhesives and pigments,such as, resin adhesive, AB adhesive, unsaturated epoxy resins,polyurethane adhesives or other adhesive that can adhere all materialstogether. The various materials surround and stick the plurality of thinsmall pieces 12. The mixed various materials forms a synthetic stonetile 14 with various patterns and specificities.

At the step 4, referring to FIG. 3, taking out the synthetic stone tile14 with the inlaid plurality of thin small pieces 12 from the largermold after the synthetic stone tile 14 is solidified. The syntheticstone tile 14 with inlaid plurality of thin small pieces 12 forms asynthetic decorative stone 10.

Finally, at the step 5, turning upside down the synthetic decorativestone 10, polishing the surface of the side with the plurality of thinsmall pieces 12.

As shown in FIG. 1, a synthetic decorative stone 10 is achievedaccording to the manufacturing method in accordance with the presentinvention, which includes a synthetic stone tile 14 and a plurality ofthin small pieces 12 inlaid therein. The patterns, shapes, and layoutmethod of the plurality of thin small pieces 12 are various according tothe desired visual effect.

The method for manufacturing a synthetic decorative stone with inlays inaccordance with the present invention utilizes modern technologies suchas ultrasonic or water jet, which brings high manufacture efficiency.Inlaying stones or other decorative materials with various patterns,shapes, and amounts into a synthetic stone tile with various layoutmethod saves stone materials, enrich the varieties of architecturaldecorative materials, and increases the decorative effect.

It is believed that the present invention and its advantages will beunderstood from the foregoing description, and it will be apparent thatvarious changes may be made thereto without departing from the spiritand scope of the invention or sacrificing all of its materialadvantages, the examples hereinbefore described merely being preferredor exemplary embodiments of the invention.

1. A method for manufacturing a synthetic decorative stone with inlayscomprising steps of: cutting or scrunching a stone or other soliddecorating materials into thin small pieces with different shapes;laying out a plurality of the thin small pieces in a bottom of a largermold according to a predetermined pattern; mixing various materialswhich can form a synthetic stone with adhesives and then dumping theminto the larger mold; taking out the mixed materials with the pluralityof thin small pieces surrounded therein from the larger mold after themixed materials is solidified, the solidified materials with theplurality of thin small pieces inlaid therein forms a syntheticdecorative stone with inlays; and polishing the surface of syntheticdecorative stone of the side with the plurality of thin small pieces. 2.The method as claimed in claim 1, wherein a cutting or scrunching toolis used for cutting or scrunching a stone or other solid decoratingmaterials into pieces.
 3. The method as claimed in claim 2, wherein thecutting or scrunching tool comprises ultrasonic or water jet.
 4. Themethod as claimed in claim 1, wherein various materials which can form asynthetic stone comprise at least one kind of materials among marblepower, quartzite power or fragments, granite power or fragments, andalumina powder.
 5. The method as claimed in claim 1, wherein theadhesives comprise resin adhesive or other adhesive materials which canadhere stone materials tight with the synthetic materials.
 6. The methodas claimed in claim 1, wherein the adhesive materials compriseunsaturated epoxy resins or polyurethane adhesives.